System and method for welding thermoplastic components to create composite structure

Abstract

A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Having thus described one or more embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following: 
     
       1. A system for welding a first thermoplastic component to a second thermoplastic component along an interface to create a composite structure, the system comprising:
 a plate element having a heated portion configured to be positioned between a portion of a first faying surface of the first thermoplastic component and a second faying surface of the second thermoplastic component, wherein the heated portion is configured to be heated to an operating temperature which is sufficient to melt the portion of the first and second faying surfaces; and 
 a manipulator mechanism configured to move the plate element along the interface from between the portion of the first and second faying surfaces, which then cool and bond together, to between a series of subsequent portions of the first and second faying surfaces, and thereby weld the first thermoplastic component to the second thermoplastic component along the interface to create the composite structure. 
 
     
     
       2. The system of  claim 1 , wherein the heated portion the plate element has a thickness of between 0.01 inches and 0.03 inches. 
     
     
       3. The system of  claim 1 , wherein the heated portion of the plate element is heated using joule heating. 
     
     
       4. The system of  claim 1 , further including a first temperature sensor configured to determine the operating temperature of the plate element, and a second temperature sensor configured to determine an adjacent temperature of the first and second thermoplastic components. 
     
     
       5. The system of  claim 1 , wherein at least the heated portion of the plate element is in physical contact with the first and second faying surfaces, and melts the first and second faying surfaces through conduction. 
     
     
       6. The system of  claim 5 , wherein a front portion of the plate element has a rake angle to control any excess melted thermoplastic material from the first and second faying surfaces. 
     
     
       7. The system of  claim 6 , wherein the rake angle is between 10 degrees and 50 degrees. 
     
     
       8. The system of  claim 1 , wherein at least the heated portion of the plate element is suspended between and not in physical contact with the first and second faying surfaces, and melts the first and second faying surfaces through radiation and convection. 
     
     
       9. The system of  claim 8 , further including a spacer element configured to create a gap between the first and second faying surfaces, wherein at least the heated portion of the plate element is located in the gap. 
     
     
       10. The system of  claim 9 , wherein the spacer element is an unheated front portion of the plate element. 
     
     
       11. The system of  claim 9 , wherein the spacer element includes one or more circular rollers. 
     
     
       12. The system of  claim 8 , further including an air nozzle configured to introduce a stream of air between at least the heated portion of the plate element and the first and second faying surfaces so as to enhance convection. 
     
     
       13. The system of  claim 8 , further including one or more holes in the plate element to enhance convection. 
     
     
       14. The system of  claim 1 , the manipulator mechanism further including a guide roller configured to guide movement of the plate element along the interface between the first and second faying surfaces. 
     
     
       15. The system of  claim 1 , the manipulator mechanism further including a pressure roller configured to press the first and second faying surfaces together behind the plate element as the plate element is moved along the interface. 
     
     
       16. The system of  claim 1 , the manipulator mechanism further including a cooling nozzle configured to deliver a cooling fluid to accelerate cooling of the first and second faying surfaces behind the plate element as the plate element is moved along the interface. 
     
     
       17. The system of  claim 1 , the manipulator mechanism further including an inert gas nozzle configured to deliver an inert gas to displace oxygen around the heated portion of the plate element. 
     
     
       18. The system of  claim 1 , further including a support surface configured to be positioned behind the first thermoplastic component, wherein the support surface is flexible so as to accommodate a deflection of the first thermoplastic component as the plate element is moved between the first and second faying surfaces. 
     
     
       19. A system for welding a first thermoplastic component to a second thermoplastic component along an interface to create a composite structure, the system comprising:
 a plate element having a heated portion configured to be positioned between a portion of a first faying surface of the first thermoplastic component and a second faying surface of the second thermoplastic component, wherein the heated portion is configured to be joule heated to an operating temperature which is sufficient to melt the portion of the first and second faying surfaces, 
 wherein at least the heated portion of the plate element is in physical contact with the portion of the first and second faying surfaces, and melts the portion of the first and second faying surfaces through conduction; and 
 a manipulator mechanism configured to move the plate element along the interface from between the portion of the first and second faying surfaces, which then cool and bond together, to between a series of subsequent portions of the first and second faying surfaces, and thereby weld the first thermoplastic component to the second thermoplastic component along the interface to create the composite structure. 
 
     
     
       20. A system for welding a first thermoplastic component to a second thermoplastic component along an interface to create a composite structure, the system comprising:
 a plate element having a heated portion configured to be positioned between a portion of a first faying surface of the first thermoplastic component and a second faying surface of the second thermoplastic component, wherein the heated portion is configured to be joule heated to an operating temperature which is sufficient to melt the portion of the first and second faying surfaces, 
 wherein at least the heated portion of the plate element is suspended between and not in physical contact with the portion of the first and second faying surfaces, and melts the portion of the first and second faying surfaces through radiation and convection; and 
 a manipulator mechanism configured to move the plate element along the interface from between the portion of the first and second faying surfaces, which then cool and bond together, to between a series of subsequent portions of the first and second faying surfaces, and thereby weld the first thermoplastic component to the second thermoplastic component along the interface to create the composite structure.